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Xenon Headlight Replacement
 
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Pelican Technical Article:

Xenon Headlight Replacement

Nick Czerula

Time:

1 hours1 hrs

Tab:

$300

Talent:

**

Tools:

Phillips & flathead screwdriver, plastic prying tool, 8mm nut driver

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)

Parts Required:

Headlight assembly, headlight bulb, active headlight or Xenon module

Hot Tip:

Do not touch bulbs with bare hands

Performance Gain:

Repair damaged headlight assembly and replace faulty headlight bulb

Complementary Modification:

Replace turn signal bulbs

Up to March 2007 production, BMW E60 vehicles with optional high intensity discharge (HID) or xenon headlights utilize a special high voltage bulb and control unit for low beam headlights. Conventional halogen bulbs are used for high beams.

From March 2007 production, the optional bi-xenon headlight is equipped with an electrically activated shutter, which directs the low beam cone of light in the same direction as the high beam. Bi-xenon headlights are also equipped with an adaptive headlight control system, which uses stepper motors to rotate the headlights slightly as the front wheels are steered, providing an enhanced lighting path as the vehicle travels through a turn.

The headlight assembly seals can wear out over time resulting in water leaks and repeat bulb failures. On models with high intensity discharge (HID) or Xenon lights, the HID module is located at the bottom of the headlight. Water can enter the module electrical connector causing headlight faults. If this happens to you, you will have to replace the headlight, the electrical harness and the HID module. The procedure below highlights Xenon style bulb replacing. Halogen bulb replacement is similar, but not covered in this tech article.

Remember that your car may have been serviced before and had parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

When replacing headlight bulbs, you can access the high beam bulb (green arrow) from inside the engine compartment.
Figure 1

When replacing headlight bulbs, you can access the high beam bulb (green arrow) from inside the engine compartment. However, the low beam bulb (yellow arrow) can only be accessed by removing the headlight assembly. I will show you how to replace the high beam bulb. Then remove the headlight assembly and service the low beam bulb and the headlight assembly module.

High beam bulb: To access the high beam bulb, rotate the access door 30 degrees and remove it from the headlight.
Figure 2

High beam bulb: To access the high beam bulb, rotate the access door 30 degrees and remove it from the headlight.

High beam bulb: Rotate the high beam bulb holder (red arrow) 45 degrees and remove it from the headlight.
Figure 3

High beam bulb: Rotate the high beam bulb holder (red arrow) 45 degrees and remove it from the headlight.

High beam bulb: Pull the headlight bulb (green arrow) out of its socket (red arrow) and replace it with a new bulb.
Figure 4

High beam bulb: Pull the headlight bulb (green arrow) out of its socket (red arrow) and replace it with a new bulb. Reverse the steps for installing. Be sure that the bulb is properly seated in the socket before trying to install it into the headlight.

Headlight assembly: Working at the radiator support, remove the hood seal (green arrow).
Figure 5

Headlight assembly: Working at the radiator support, remove the hood seal (green arrow). Lever out one side of the assembly (inset) to release the retaining clips. Then work your way along the seal, detaching it until it's free.

Headlight assembly: Then, remove the five T30 Torx bumper cover fasteners (green arrows).
Figure 6

Headlight assembly: Then, remove the five T30 Torx bumper cover fasteners (green arrows).

Headlight assembly: Working at the top of the headlight, remove the two T30 Torx fasteners (green arrows).
Figure 7

Headlight assembly: Working at the top of the headlight, remove the two T30 Torx fasteners (green arrows). Then loosen the two 8mm fasteners (red arrows, inset) about four turns.

Headlight assembly: Pull the corner of the bumper cover away from the headlight and hold it.
Figure 8

Headlight assembly: Pull the corner of the bumper cover away from the headlight and hold it. Then slide the headlight assembly toward the front of the vehicle until it is out of the lower fasteners. Then remove it from the vehicle. For example, slide the left headlight out toward the left and the right headlight out toward the right.

Headlight assembly: Disconnect the headlight electrical connectors.
Figure 9

Headlight assembly: Disconnect the headlight electrical connectors. Slide the main electrical connector lock down to unlock it. Then pull the connector straight off the headlight. Then remove the smaller connector by pressing the release tab and pulling it straight off (inset). Once disconnected, remove the headlight from the vehicle and place it on your workbench.

Headlight assembly: Remove the low beam access door by pressing the release tabs (green arrows) and removing.
Figure 10

Headlight assembly: Remove the low beam access door by pressing the release tabs (green arrows) and removing. Fold it down and then pull it out of the lower mounts.

Headlight assembly: Flip the locking spring (green arrow) off the headlight.
Figure 11

Headlight assembly: Flip the locking spring (green arrow) off the headlight. Then rotate the bulb holder 5 degrees to remove it. The electrical connector will automatically release (red arrow).

Headlight assembly: Pull the bulb holder off to remove it.
Figure 12

Headlight assembly: Pull the bulb holder off to remove it. Then squeeze the bulb retaining springs to detach them and allow them to rest at the side of the bulb. Pull the bulb straight out of the headlight to remove it. Reverse the steps to install a new bulb. Do not touch the bulb with your bare skin.

Headlight assembly: Flip the headlight over to service the control modules.
Figure 13

Headlight assembly: Flip the headlight over to service the control modules. To remove the active headlight controller, remove the three T20 Torx fasteners (red arrows). To remove the Xenon headlight module, remove the three T20 Torx fasteners (green arrows).

Headlight assembly: When removing the Xenon module, inspect the module for corrosion (green arrow).
Figure 14

Headlight assembly: When removing the Xenon module, inspect the module for corrosion (green arrow). If needed, replace the module as well as the headlight. When removing the active headlight module, inspect the module for corrosion (red arrow). If needed, replace the module as well as the headlight. Reverse the instructions for reinstallation.






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Comments and Suggestions:
VP Comments: 2009 BMW 535xi. Replaced xenon bulb but light still does not work. How to determine if a new xenon module is needed? If the module is not an issue, how to determine if the fuse is out? All wires look good. What else could it be? The new xenon bulb was purchased from a BMW dealership parts store.
November 4, 2016
  Followup from the Pelican Staff: You can swap the module from the other side.

To test fuses or the circuit, grab a repair manual with a wiring diagram. Then use the wiring to trace the circuit and locate fuses.- Nick at Pelican Parts
 
Toni Comments: My 2007 530I with bi-xenon with 'Adaptive Headlight Control' self-leveling headlights was manufactured on 10/2006.
I need to change headlamp bi-xenon only, not the flashing lamp.
Do you all know if it is D1S or D2S type for this model?
Can you include the link to part to buy if you know?
Thanks
July 6, 2016
  Followup from the Pelican Staff: I’m not the best with part numbers.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.

- Nick at Pelican Parts
 
Habib Comments: Hey so I have a 2008 bmw 550i and I need a new headlight. Was wondering are bmw 550 series from 2004 to 2010 all compatable. Does a headlight from 2007 bmw fit in a 2008?
May 15, 2016
  Followup from the Pelican Staff: Not all. I believe there was a facelift at the halfway point. Plus Xenon verse tungsten lighting.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need. - Nick at Pelican Parts
 
shuabarr Comments: Sorry Nick, I put it all back together before taking a photo. The collar had clip that help it closed. Undo the clip and the collar hinges open. Connect the collar to the new igniter using the alignment pins for placement.
May 13, 2016
  Followup from the Pelican Staff: Ok, no problem. Thanks for the info, I appreciate the follow up. - Nick at Pelican Parts  
shuabarr Comments: On my 2006 530xi, there are no retaining springs to hold the xenon bulb in the housing. Instead there is a threaded collar which can be removed from the old bulb and installed on the new one. The electrical connector is held on by some thin metal clips.
May 11, 2016
  Followup from the Pelican Staff: Can you share a photo? With the igniter removed, if there is a collar, unscrew it, then transfer to the new bulb. - Nick at Pelican Parts  
Matthew K Comments: I have replaced one of my pre LCI zenon headlights but now they don't self level. Do they require coding to the car, both sides are affected.
March 16, 2016
  Followup from the Pelican Staff: Yes, I would assume so. The Xenon modules have to be programmed. - Nick at Pelican Parts  
Mike Comments: Does anyone know if the Adaptive Xenon headlamp assemblies that cast about $1200 each can be replaced with the non Xenon which are about $570 each? 2006 530IX
December 14, 2015
  Followup from the Pelican Staff: Not without modification of the wiring / control module. - Nick at Pelican Parts  

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Page last updated: Fri 12/9/2016 02:38:28 AM